Reinforced wall structure

ABSTRACT

A large buoy construction of relatively thin wall composite material, which walls are integrally formed and interconnected by a reinforcing matrix frame comprising reinforcing members sandwiched between layers of screens, to which the cement type material can be applied by use of power equipment in a rapid application and thorough penetration into the matrix to accomplish on-site formless molding of integral, unitary structures having complex shapes and junctions.

Waited tates mm [191 Dewey, Jr. et ai.

REIINIFDRCED WALL STRUCTURE Inventors: David B. Dewey, Jr., Rancho SanteFe, Norman W. Schotieid, San Diego, both of Calif.

Assignee: General Dynamics Corporation, San

Diego, Calif.

Filed: June 3, 1971 Appl. No.: 149,576

Related 1.1.8. Application Data Division of Ser. No. 827,636, May 26,1969, Pat. No.

US. Cl. ..52/251, 52/260, 52/449, 52/454, 52/650 Int. Cl. ..E04b 1/16Field of Search ..52/743, 251, 260, 339, 344, 52/650, 422, 378, 371,342, 343, 454, 449; 264/35, 309

References Cited UNITED STATES PATENTS 6/1967 Gamber ..52/251 2/1971Day, Jr. ..52/251 10/1934 Dickson ..52/454 ]Marclh 20, 1973 3,015,1941/1962 Clark ..52/378 2,964,821 12/1960 Meehan ..52/378 3,363,371 1/1968 Villalobos ..52/454 2,104,878 1/1938 Magnuson ..52/344 1,344,9296/1920 Stainer ..52/251 2,147,677 2/1939 Patterson .....52/344 1,324,02712/1919 Block ..52/422 FOREIGN PATENTS OR APPLICATIONS 1,000,347 2/1952France ..52/378 Primary Examiner-Henry C. Sutherland AssistantExaminer-Leslie A. Braum Attorney-John R. Duncan, Neil F. Martin andCarl R. Brown [5 7] ABSTRACT A large buoy construction of relativelythin wall composite material, which'walls are integrally formed andinterconnected by a reinforcing matrix frame comprising reinforcingmembers sandwiched between layers of screens, to which the cement typematerial can be applied by use of power equipment in a rapid applicationand thorough penetration into the matrix to accomplish on-site formlessmolding of integral, unitary structures having complex shapes andjunctions.

5 Claims, 13 Drawing Figures PATENTEDMAR20 I975 'FIG.3

3,721,058 SHEET 10F 5 I NVEN TOR.

.DAVID B. DEWEY JR.

NORMAN W. SCHOFIELD gammy ATTORNEY PATENTEU MAR 20 I975 SHEET 2 CF 5 3 vv9 wv II om m9 :Iillv ll. 7 w V 2w mm No. mm

INVENTOR. DAVID B. DEWEY JR.

M BY NOR AfSCHOFIELD ATTORNEY PATENTEmmzo I973 3HEET 3 0F 5 FIG?INVENTOR. DAVID B. DEWEY JR.

NORMAN W. SCHOFIELD KM PIC-3.13

ATTORNEY PATENTED MAR 2 0 i973 SHEET a 0F 5 K m m V m DAVID B. DEWEY JR.

NORMAN W. SCHOFIELD ATTORNEY PATENTEDMARZOW 7 3,721,058

' SHEET 50F 5 FIGS FIGJI INVENTOR,

DAVID B. DEWEY JR. NORMAN W. SCHOFIELD FIG |2 ATTORNEY REINFORCED WALLSTRUCTURE CROSS-REFERENCE TO RELATED APPLICATION This application is adivision of our copending U. S. patent application Ser. No. 827,636,filed May 26, 1969 now US. Pat. No. 3,622,656.

BACKGROUND OF THE INVENTION Buoys have long been used as navigationalaids in bodies of water. With the increased use of electronic equipmentin providing navigational information to passing ships and the like, ithas been necessary to increase the size of such navigational buoys toprovide ease of access to the internal volume of the buoys to serviceelectronic navigation equipment and to provide a relatively stableplatform for antennas. While these large buoys may be constructed in theconventional manner of constructing ships, such as by use of known steelfabrication techniques, such steel fabricated buoys are expensive andtime consuming to construct and require considerable maintenance topreserve the steel structure. Thus it is advantageous to make such largebuoys by other construction techniques, such as by making the buoys ofconcrete.

While large buoys constructed of concrete have advantages, the normaltechniques for constructing concrete vessels present constructionproblems. The walls of the concrete vessel cannot be too thick or thestructure becomes too heavy. Further the vessel or buoy requiresinternal bracing that has complex shapes and complex junctions that aredifficult to efficiently fabricate using known processes and techniques.To construct such complex structures from separately formed wallelements, requires the wall elements to be separately fabricated andthen assembled. This makes it difficult to achieve unitary strength andthe use of the separate forming steps is time consuming, expensive, anddifficult to accomplish. Thus it is advantageous to have a new andimproved concrete buoy structure and method of making the structure thatprovides a large and inexpensive buoy that is integrally formed on sitein a quick and inexpensive manner and with a minimum use of forms, andwhich structure may employ power tools to obtain optimum application ofcement material to a steel reinforcing frame work.

SUMMARY OF THE INVENTION In an exemplary embodiment of this invention, alarge buoy is constructed from thin wall composite material that hassteel fibers strategically placed in mixed cement material. These steelfibers are sandwiched between screen layers such as wire mesh and metallath form a matrix to which air-accelerated, premixed cement bindermaterial is rapidly applied with thorough penetration into the matrix.In one mode of wall construction, one of the screen layers is relativelyopen and the other screen layer on the opposite side of the steel fibersis relatively dense. The cement binder material is projected from adischarge nozzle through the relatively open screen layer and againstthe relatively dense screen layer. The relatively dense screen layerstops the projected cement mixture, with the mixaround the steel fibersand the relatively open screen, providing a wall structure that has auniform thickness and is made without forms. This is accomplishedthrough use of power tools and achieves a wall without voids therein.Thus the formless molding of the relatively thin wall achieves anoptimum working of the cement material into the steel reinforcingwithout requiring hand working. The use of this method of constructionfacilitates fabrication complex shapes and complicated junctions of thebuoy structure and allows final unitary construction of the entire buoyat a given site. The steel reinforcing matrix is integrally tiedtogether to form an entirely enclosed composite buoy frame with internalwalls, to which the cement mixture is applied.

The vessel or buoy construction has a relatively large size with aplurality of walls and bulkheads that provide internal, integral supportand water-tight areas for the storing of navigational equipment. Thestructure is made substantially entirely of a cement mixture with steelreinforcing, and yet has relatively thin walls and thus considerablebuoyancy for its size. The buoy has means for towing and has a uniquefender structure for protecting the outer edges.

It is therefore an object of this invention to provide a new andimproved buoy construction.

It is another object of this invention to provide a new and improvedmethod of constructing reinforced thin wall composite materialstructures.

It is another object of this invention to provide a new and improvedbuoy structure employing a new and improved method of constructingreinforced thin wall concrete structures in which the entire buoyconstruc tion is fabricated in place.

It is another object of this invention to provide a new and improvedconcrete buoy construction in which the handling damage to bulkheads isreduced, the overall drying time for the cement mixture in the buoy isreduced, greater control over the application of the cement mixture tothe reinforcing structure is increased and the cement mixture can beapplied in less time than in previous methods.

It is another object of this invention to provide a new and improvedmethod of constructing reinforced thin wall concrete structures in whichuse of forms to make complex shapes and complicated junctions areeliminated and the cement binding material is applied mechanically toreduce voids.

Other objects and many advantages of this invention will become moreapparent upon a reading of the following detailed description and anexamination of the drawings wherein like reference numerals designatelike parts throughout and in which:

FIG. I is a side elevational view of a buoy construction of thisinvention.

FIG. 2 is a top view with parts broken away showing the internalconstruction of the buoy structure of FIG. 1.

FIG. 3 is a cross sectional view taken along lines 3-3 of FIG. 2 withparts broken away.

FIG. d is a perspective view with parts broken away illustrating themanner of constructing intersecting wall panels employing the method andstructure of this invention.

FIG. 5 is a side view illustrating the power application of cementbinding material to the reinforcing steel matrix to construct thin wallpanels without forms in the manner of this invention.

FIG. 6 is a perspective, diagrammatic view illustrating another methodof constructing intersecting wall panels.

FiG. 7 is a diagrammatic illustration of the internal walls and bulkheadstructure of another embodiment of the buoy structure.

FIG. 8 is a perspective view with parts broken away illustrating thearrangement of steel reinforcing in the integral construction ofbulkheads, walls and hulls of the buoy structure.

FiG. 9 is a cross sectional illustrative view with parts broken away ofanother mode of constructing joined wall panels.

FIG. 10 is a perspective view with parts broken away illustrating theframe reinforcing structure of an open wall portion of the buoyconstruction.

FIG. 11 is a cross sectional illustrative view of the lower portion ofthe open wall structure of FIG. 10.

FIG. 12 is a perspective view with parts broken away of the towing framestructure.

FIG. 13 is a perspective view of a fender structure on the buoy.

Referring now to FIG. 1, a large buoy structure 10 has a circular hull14 with slanted bottom surface 16 and vertical sides 18. The upper deck22 of the buoy 10 has rungs 19 facilitating movement from the side ofthe buoy 10 to a central column 12. Bulkhead hatches 21 allows access tothe internal volume of the buoy structure 10 and a water-tight door 24allows access through center column 12 to the internal volume of thebuoy structure. The upper super structure 26 of the center column 12,supports navigational aid equipment such as radar antennas, transmittingand receiving antennas, lights, and the like. As a representative sizefor the buoy structure 10, the hull diameter may be about 40 feet with a7 1% foot depth and the central column 12 having a diameter of about 6feet and a height as determined by the particular use of the buoystructure. It should be understood that these dimensions and otherdimensions hereinafter given relative to the buoy structure arerepresentative only.

Referring now to FIGS. 2, 3, 4, and 5, the buoy structure comprises thinwall panels of composite material that are formed of steel reinforcingbars and wire mesh that are covered with a cement binder material. Thebottom surface of the hull 14 comprises two layers 90 of welded wiremesh that, for example, may comprise 16 gauge wire having an openingspacing of approximately 1 inch by one-half inch. Positioned above thelayers of welded wire mesh 90 are interlocking reinforcing, re-barmembers 46 and 48 that may be made of steel. Re-bars 48 extend radiallyfrom the center of the structure or from the central column 12 to theouter side of the hull l4 and re-bars 46 and 47 are circular and areconcentrically spaced from the central column 12 to the outer edge ofthe hull l4 and up the sides 18 of the buoy 10. Also extending radiallyoutward from the center column 12 are beam members 44 that have openings104 out therein along their length for passing re-bars 47. Re-bars 46pass underneath the lower edge surface of the beam members 44 and abovethe lower welded wire mesh 90. A second layer of welded wire mesh 92rests on the top of the upper re-bars 47 and are positioned between eachof the radially extending beam members 44, see FIG. 4.

The wall members, as for example wall member 32, comprises verticalre-bar members 76 that are rigidly secured, by butt-welds 106 or byother suitable joining techniques, integrally to the upper surface ofthe beam 44. Positioned on one side of the vertical re-bars 76 is a pairof sheets of welded wire mesh 94 and on the opposite surface of re-bars76 is positioned a pair of sheets of expanded metal lath 96. Theexpanded metal lath 96 may, for example, be 3.4 pound expanded metallath having diamond shaped openings that are approximately one-fourth bythree-eighths inch. The thickness of the expanded metal lath is in theorder of one-sixteenth of an inch. This structure, as illustrated inFIGS. 3, 4, and 5, extends throughout the hull of the buoy structure 10.This structure also extends outwardly to where the beam members 44 angleupwardly at to form the slanted bottom 16 and then bend vertically toform the vertical sides 18. The vertical beam members 56 are secured toupper beams 66 that extend horizontally above the beam members 44. Thecircular slanted bottom 16 has the same structure as the bottom of hull14 with the circular re-bar members 58 encircling the hull structure.Positioned on the upper surface of the radial beam members 66 to formthe deck 22, are circular and concentrically arranged re-bar members 68that are spaced radially outward to the side 18 and then continue downas re-bar members 58 providing a continuous circular re-bar enclosure.Holes are not placed in beams 56 and 66 for passing re-bars 58 and 68therethrough. In the structure of the deck 22, the previously describedlayers of expanded metal lath 96 of FIG. 4 are positioned on theunderneath surface of the beam members 66 and with their edgesoverlapping the metal lath 96 and the welded wire mesh 94 at eachintersection with the vertical walls 32, substantially as illustrated inFIG. 9. Welded wire mesh 70 is then positioned on the upper surface ofthe re-bars 68.

The process of applying the cement mixture to the reinforcing framestructure previously described is accomplished in the manner illustratedin FIGS. 4 and 5. Generally a base form, not shown, that may be made ofany suitable material such as plywood, steel, or the like, isconstructed and supported to provide a rigid form for supporting thelower reinforcing structure of the buoy, namely the lower hull wall andthe angled side hull wall 16. The outer side walls 18 of the hull havethe same structure as previously described relative to the deck 22 andthe center walls 32. The cement mixture, which may comprise a mixture ofone and one-half part sand to each one part cement, is premixed withwater and projected under force through a known plastering machinedispensing nozzle 122. The nozzle 122 utilizes air under pressure toforce the cement mixture in the form of a stream into the structure. Theair pressure has sufficient force to force the cement mixture throughthe welded wire mesh 94 into the expanded metal mesh 96. The cementmixture, when impacting against the metal mesh 96, passes through theopenings in the double layered mesh in sufficient quantities to extendonly slightly out the openings as illustrated in FIG. 5. Through correctmaneuvering of the nozzle I22, the amount of cement mixture depositedinto the welded wire mesh 114 and 116 extends only slightly outside thismesh. Accordingly, by means of dressing up the surfaces on each side ofthe vertical wall members, the cement binding material is completelydistributed into the wall structure and only a slight amount ofsmoothing of the outer surface is necessary to provide the thin wallconcrete structure. Since the lower hull structure is resting on forms,the cement mixture 168 (FIG. 4) is projected by nozzle 122 directly intothe reinforcing structure and against the form underneath these hullstructures. Thus the cement material 108 is deposited by nozzle 122 in adirect manner onto the form surface and the material passes through therelatively open layers of welded wire mesh 90 and 92. The corners of thejoints may be shaped into the configuration illustrated in FIG. 9. Thusit may be seen that the joints between the hull and the walls areintegrally connected by integral reinforcing members and the cementmixture is applied thereto in a quick and efficient manner to providethe thin wall structures without requiring forms for other than thebottom of the hull'structure. The entire structure may be sprayed in arelatively quick and efficient manner with power equipment. The cementmixture is normally applied to the deck 22 after the hull and wallmembers have been constructed. The reinforcing deck structure is thencovered with the cement mixture and the lower surface of the layers ofexpanded metal lath holds the cement mixture in the manner of the wallconstruction illustrated in FIG. 5. The deck 22 is thus constructedwithout forms. Also in forming the lower hull structure, mechanicalagitators or tampers may be used to assure complete mixture of thecement mixture into the layers of wire mesh 90 and 92 and around there-bars 46, 47, and 48.

It should be recognized that the use of the frames of re-bars sandwichedbetween the layers of welded wire mesh and expanded metal lath coveredwith the cement mixture, provides a very strong reinforced concrete wallSII'UCIIHCvHOWBVCI the method that allows the use of mechanical means,such as nozzle 122, to force the cement mixture into frames; providescomplete mixing of the cement mixture with the re-bars, mesh and laththat eliminates voids and spaces in the walls that could cause leakingand other problems. Further the ability of being able to apply thecement mixture to the walls without forms, allows visual inspection ofthe structures to assure complete mixing of the cement mixture with theframes and without voids.

In further describing the buoy structure, the steel central column 12has a lower wall 30 that extends below the surface of the bottom of thehull l4 and has a circular outer shoulder. The central column has aladder 74 and a bulkhead opening 43 for access to the four compartments.The wall portions 32 and 39 extend to an inner wall 34, 36 and 37 thatprovides an internal compartment for storing various equipment, such asnavigational equipment. Bulkhead openings 38 permit access between thefour compartments. The deck 22 has at least one equipment opening 21that is secured in the known manner and locked from the inside of themain compartment. Other deck access openings are of the circular manholetype and bolt in place over the peripherial compartments. A marinefender 60, that may be made of resilient material, is held by bolts 62around the outer circumference of the hull structure. An upwardlyprojecting plate 64 is welded to the beam 66 and provides a means forsecuring a tow line or mooring chain to the buoy 10. The entire exteriorsurface of the main deck of the buoy is normally coated with a non-skidpaint and a protective paint coating is applied to the other metal andconcrete surfaces of the buoy. Thus the entire structure is constructedin place with the reinforcing members integrally connected. Thecombination reinforcing frame using the expanded metal lath avoids voidsin the cement binder, reduces or eliminates excessive vibration time,and reduces the problem of lack of dimensional control of wallthicknesses.

A modified structure, see FIG. 6, comprises the replacement of the beams44, 56, and 66 with three rebar members and 132. In this construction, acentral re-bar member 130 has vertical re-bar members 134, weldedthereto at 138. In this particular modified embodiment, the verticalre-bars 134 have only a short length allowing the layout of the bottomframe structure and then laying out of the reinforcing frames of thewall structure 152. In this construction, the circular rebars 126 and'128 are positioned above and below the radially directed re-bar members130 and 132. Layers of welded wire mesh and 1142 provide the bottomreinforcing structure in the same manner as previously described in FIG.4. The wall structures 152 have the same structure as that describedrelative to FIG. 4 with the expanded metal lath positioned on one sideof the re-bar members 136 and the layers of welded wire mesh 148positioned on the opposite side of the re-bar members 136. The adjacentends of the re-bar members 136 and 134 are tied together by wires or thelike to hold the wall members in position for receiving the cementbinder material.

In still another embodiment, see FIG. 9, the three rebar members 220,222, and 224 are directed radially outward from the central bulkhead 30with the vertical re-bar members 238 being welded at their bottom endsto the central re-bar 222 and at their upper ends to the central re-bar228 of the group of three re-bar members 226, 228, and 230 that form thedeck reinforcing structure. This same deck reinforcing structure is employed and secured to the upper'ends of the re-bar members 136 in'FlG.6. In the embodiment illustrated in FIG. 9, the layers of expanded metallath 246 extends from the upper three re-bar members to the lowerre-bars 234. The ends of the upper layers of welded wire mesh 235overlap the lower ends of the expanded metal lath 246 and at the upperends, the layers of expanded metal lath 256 overlap the upper edges ofthe expanded metal lath 246. This provides an integral connection of there-bar reinforcing structure and the cement binder material forming anintegral wall structure with angled corners 250 and 252.

In another form of the hull structure, the four inner compartments, seeFIG. 7, are defined by a circular outer bulkhead 164 having inner walls172, 174, and 176 with a steel central column 168 having access openings170. In this structure, and employing the modified structuralarrangement of FIGS. 6 or 9, the frame structure comprises the threeradially extending re-bar members 186, see FIG. 8, with vertical re-barmembers 184 being secured to the central re-bar mem bers 182 and 188.Circular re-bars 196 encircle the lower wall of the hull in the mannerpreviously described. The three re-bar members 186 are integrallyconnected with re-bar members 190 that in turn are integral with theside re-bar members 192. The side rebar members 192 are connected to theupper radially extending deck re-bar members 180 or 270 in the mannerillustrated in FIG. 10. This provides a complete integral structurethroughout the radial dimensions of the hull structure. The tie linesecuring plate 208 having an opening 210, see FIGS. 8, 12 and 13, issecured to the various connecting re-bar members 180, 182, 188, 192,212, 308, and 310 as illustrated. Also secured to the outer edge surfaceof the plate 208 is a plate 304 having an opening 306 as seen in FIG.13. The plate 208 with lower portion 314 and the re-bar members areembedded into the cement binder material 348 with only the ends 208 and304 projecting.

As previously described, only certain ones of the radial extending wallmembers are closed, as for exam ple wall members 172, 174 and 176, toprovide enclosed equipment compartments. Other wall members are open andhave a reinforcing frame construction as illustrated in FIG. 10. In thisconstruction, see FIGS. and 11, and L-shaped beam member 274 is securedto vertical re-bar member 276 that are in turn welded to the centerre-bar member 278 of the group of radially extending re-bar members 278,280 and 282. In this structure the upper welded wire mesh 298 and thelower welded mesh 296 function in the manner previously described andare held by a cement binder material 302 in the manner previouslydescribed. Further for this limited vertical wall structure, the weldedwire mesh 294 and expanded metal lath 292 support the cement mixture inthe manner previously described. One of the ends of the beam member 274is secured to the central column 168 with the other ends secured to thethree re-bar members 190 by welding or other suitable techniques.Vertical re-bar members 200 connect to the circular rebar 202 at theintersection of the bottom of the hull with the angled bottom 16 andextend circumferentially around the hull structure providing thereinforcing frame for the outer circular wall 164. Upper re-bar members206 pass under and abut against the radially extending re-bar members270. As additional structure support, chine beam members 284 are securedat spaced intervals between each of the short wall members 166 and 167and are secured to re-bar members 286 that are in turn secured to theintegral re-bar members 285, 288 and 290. The radially extending re-barmembers 191 pass under the re-bar member 288 to provide an integralframe reinforcing structure. This entire structure, as illustrated inFIGS. 8, 10 and 12, is secured together by the cement binding materialin the method and manner previously described and this structureprovides a larger internal equipment area than the structure illustratedin FIG. 2.

In a modified form of the fender of FIG. 3, a fender, see FIG. 13, issecured to the plate member 304. The fender comprises a plurality ofelongated resilient bar members 322 and 346 having flat surfaces thatabut against the outer wall 332 of the buoy hull. Cables 326 and 342extend through channels 324 and 344 between the plates 304, and turnbuckles 338 provides means for tightening cables 326 and 342 to hold theresilient fenders 322 and 346 in position. Also in FIG. 13 the curvededge 348 of the hull structure is illustrated.

With reference to the structures illustrated in FIGS. 7, 8 and 10, thewall members of FIG. 8 correspond, for example, to the wall members 172of FIG. 7. There are four of these wall structures in the buoyconstruction. The wall structure of FIG. 10 corresponds to the wallstructures 166 and 167 as illustrated in FIG. 7. The chine structures ofFIG. 10 are positioned in intervals, as illustrated by the chinestructures 54 of FIG. 2. As an example only, the re-bar members in FIG.8 and 270 in FIG. 10, may be three-fourths inch steel bars and thevertical re-bar members 184 and 276 may be one-half inch steel barmembers.

Having described our invention, we now claim.

1. An integral intersecting concrete wall structure having a base walland a side wall, wherein said base wall comprises:

at least one bottom layer of open wire mesh;

a plurality of longitudinally spaced reinforcing bars located above saidbottom layer of open wire mesh;

a plurality of laterally spaced reinforcing bars located above saidlongitudinally spaced reinforcing bars;

a second plurality of longitudinally spaced reinforcing bars locatedabove said laterally spaced reinforcing bars;

at least one top layer of open wire mesh located above said secondplurality of longitudinally spaced reinforcing bars;

a concrete binder material surrounding substantially all of saidlongitudinally and laterally spaced reinforcing bars and forming top andbottom base wall surfaces, said bottom surface being located below saidbottom layer of open wire mesh and said top wall surface being locatedabove said top layer of open wire mesh;

at least one base intersection beam located within said concrete bindersuch that a top portion of said intersection beam projects above saidtop wall surface; and

wherein said side wall comprises:

at least one outside layer of open wire mesh, said mesh parallel to andoverlapping the outside surface of the projecting portion of said baseintersection beam of said base wall;

at least one inside layer of dense screen material parallel to saidoutside layer of open welded wire mesh and overlapping the insidesurface of a portion of said base intersection beam;

a plurality of side wall reinforcing bars spaced along the length ofsaid intersection beam and structurally attached to the projectingportion of said base intersection beam, which plurality of side wallreinforcing bars lies between said outside layer of open wire mesh andsaid inside layer of dense screen material that are at an angle to saidbase wall; and

a concrete binder material surroundings substantially all of said sidewall reinforcing bars and forming inside and outside wall surfaces thatare at an angle to said base wall, said inside surface being locatedinside of said inside layer of dense screen material and said outsidewall surface being located outside of said outside layer of open wiremesh.

2, The integral intersecting concrete wall structure of claim whereinsaid intersection beam comprises:

a plurality of closely spaced reinforcing bars lying approximatelymutually parallel, and

a plurality of short reinforcing bars spaced along one of said pluralityof closely spaced reinforcing bars and structurally attached thereto atapproximately right angles, which plurality of short reinforcing barshas a portion projecting above said top wall surface.

3. The integral intersecting concrete wall structure of claim 20 whereinsaid intersection beam comprises a structural beam having an upper andlower cap and a web therebetween, wherein said lower cap and a portionof said web are located within said base wall and the upper cap and atop portion of said web projects above said top wall surface. 7

4. The integral intersecting concrete wall structure of claim 20 havingadditionally a ceiling wall comprising:

at least one bottom layer of dense screen material;

at least one upper layer of open wire mesh;

at least one ceiling intersection beam structurally secured to the upperends of said side wall reinforcing bars;

a plurality of ceiling reinforcing bars spaced along said ceilingintersection beam in intersecting relationship and laying between saidbottom layer of dense screen material and upper layer of open wire mesh;and

a concrete binder material surrounding substantially all of said ceilingreinforcing bars and a top portion of said ceiling intersection beam andforming top and bottom ceiling wall surfaces, said bottom surface beinglocated below said dense screen material and said top ceiling wallsurface being located above said open wire mesh.

5. The intersecting concrete wall structure of claim 23 wherein:

a layer of said open wire mesh has openings of approximately 1 byone-half inch; and

a layer of said dense screen material has openings of approximatelyone-fourth by three-eigths inch.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,721,058 Dated March 20, 1973 David B. Dewey, Jr. Norman W. Schofield.It is certified that error appears in the aboveidentified patent andthat said patent is hereby corrected as shown below:

In the second line of Claims 2, 3 and 4 delete "claim 20" and replacewith claim l-.

In the first and second lines of Claim 5 delete "claim 23" and replacewith -claim 4.

Signed and sealed this 18th (1a of December 1973 (SEAL) Attest;

EDWARD M.PLETCRER,JR. RENE D. TECTMRYER Attestlng Officer ActingCommissioner of Patents

1. An integral intersecting concrete wall structure having a base walland a side wall, wherein said base wall comprises: at least one bottomlayer of open wire mesh; a plurality of longitudinally spacedreinforcing bars located above said bottom layer of open wire mesh; aplurality of laterally spaced reinforcing bars located above saidlongitudinally spaced reinforcing bars; a second plurality oflongitudinally spaced reinforcing bars located above said laterallyspaced reinforcing bars; at least one top layer of open wire meshlocated above said second plurality of longitudinally spaced reinforcingbars; a concrete binder material surrounding substantially all of saidlongitudinally and laterally spaced reinforcing bars and forming top andbottom base wall surfaces, said bottom surface being located below saidbottom layer of open wire mesh and said top wall surface being locatedabove said top layer of open wire mesh; at least one base intersectionbeam located within said concrete binder such that a top portion of saidintersection beam projects above said top wall surface; and wherein saidside wall comprises: at least one outside layer of open wire mesh, saidmesh parallel to and overlapping the outside surface of the projectingportion of said base intersection beam of said base wall; at least oneinside layer of dense screen material parallel to said outside layer ofopen welded wire mesh and overlapping the inside surface of a portion ofsaid base intersection beam; a plurality of side wall reinforcing barsspaced along the length of said intersection beam and structurallyattached to the projecting portion of said base intersection beam, whichplurality of side wall reinforcing bars lies between said outside layerof open wire mesh and said inside layer of dense screen material thatare at an angle to said base wall; and a concrete binder materialsurroundings substantially all of said side wall reinforcing bars andforming inside and outside wall surfaces that are at an angle to saidbase wall, said inside surface being located inside of said inside layerof dense screen material and said outside wall surface being locatedoutside of said outside layer of open wire mesh.
 2. The integralintersecting concrete wall structure of claim 20 wherein Saidintersection beam comprises: a plurality of closely spaced reinforcingbars lying approximately mutually parallel, and a plurality of shortreinforcing bars spaced along one of said plurality of closely spacedreinforcing bars and structurally attached thereto at approximatelyright angles, which plurality of short reinforcing bars has a portionprojecting above said top wall surface.
 3. The integral intersectingconcrete wall structure of claim 20 wherein said intersection beamcomprises a structural beam having an upper and lower cap and a webtherebetween, wherein said lower cap and a portion of said web arelocated within said base wall and the upper cap and a top portion ofsaid web projects above said top wall surface.
 4. The integralintersecting concrete wall structure of claim 20 having additionally aceiling wall comprising: at least one bottom layer of dense screenmaterial; at least one upper layer of open wire mesh; at least oneceiling intersection beam structurally secured to the upper ends of saidside wall reinforcing bars; a plurality of ceiling reinforcing barsspaced along said ceiling intersection beam in intersecting relationshipand laying between said bottom layer of dense screen material and upperlayer of open wire mesh; and a concrete binder material surroundingsubstantially all of said ceiling reinforcing bars and a top portion ofsaid ceiling intersection beam and forming top and bottom ceiling wallsurfaces, said bottom surface being located below said dense screenmaterial and said top ceiling wall surface being located above said openwire mesh.
 5. The intersecting concrete wall structure of claim 23wherein: a layer of said open wire mesh has openings of approximately 1by one-half inch; and a layer of said dense screen material has openingsof approximately one-fourth by three-eigths inch.